Predicting Deposition Geometry and Material Flow in Friction Surfacing via SPH Simulation
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This study presents a meshfree simulation framework for modeling the Friction Surfacing (FS) process using the Smoothed Particle Hydrodynamics (SPH) method. The developed 3D SPH model accurately captures the thermo-mechanical behavior of FS, successfully predicting key deposition characteristics such as geometry, material flow, and flash formation. Simulation results align well with experimental observations in terms of deposited layer thickness, width, and thermal profiles. The model provides valuable insights into the primary heat sources during FS. Furthermore, the spatial distribution of shear stress and temperature allows the identification of conditions under which material bonding is most likely to occur. The framework offers a predictive tool to enhance the understanding of deposition mechanisms and improve process control in FS-based additive manufacturing.